Rating:
Information injection-pump assembly
ZEXEL
107692-0040
1076920040
Service parts 107692-0040 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
16600-95016
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/21.6{220}
15.
NOZZLE SET
Include in #1:
107692-0040
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
107692-0040
1076920040
Zexel num
Bosch num
Firm num
Name
107692-0040
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-4120
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
PS/ACT control unit part no.
407910-3
03*
Selector switch no.
01
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
15
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
5.6
5.57
5.63
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
14.8
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
115.4
113.4
117.4
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
9.5
7.7
11.3
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(14.8)
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
115.4
114.4
116.4
Basic
*
Fixing the lever
*
Boost pressure
kPa
80
80
Boost pressure
mmHg
600
600
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Injection quantity adjustment_04
Adjusting point
B
Rack position
R2(R1-2.
65)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
94.8
90.8
98.8
Fixing the lever
*
Boost pressure
kPa
80
80
Boost pressure
mmHg
600
600
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2-1.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
53.1
49.1
57.1
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1-2.45
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
92.9
88.9
96.9
Fixing the lever
*
Boost pressure
kPa
80
80
Boost pressure
mmHg
600
600
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R2-1.5
Boost pressure
kPa
12
8
16
Boost pressure
mmHg
90
60
120
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R2-0.4
Boost pressure
kPa
45.3
44
46.6
Boost pressure
mmHg
340
330
350
Boost compensator adjustment_03
Pump speed
r/min
500
500
500
Rack position
R2(R1-2.
65)
Boost pressure
kPa
66.7
66.7
66.7
Boost pressure
mmHg
500
500
500
0000001601
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.5
2.45
2.55
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_02
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.6
5.57
5.63
Output voltage
V
1.2
1
1.4
Confirmation
*
_03
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
_04
CU407910-303*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.5
2.45
2.55
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_05
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.6
5.57
5.63
Output voltage
V
1.2
1
1.4
Confirmation
*
_06
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
----------
T1=F52 BCL=1.5+-0.1mm
----------
----------
T1=F52 BCL=1.5+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)-
----------
----------
a=25.5deg+-5deg b=(40deg)+-3deg
----------
----------
a=25.5deg+-5deg b=(40deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)-
(2)Set the stopper bolt so that speed = aa and rack position = bb. Confirm non-injection. Next, confirm non-injection at speed = cc.
----------
aa=1400r/min bb=5-0.5mm cc=300r/min
----------
a=20deg+-5deg b=37deg+-5deg
----------
aa=1400r/min bb=5-0.5mm cc=300r/min
----------
a=20deg+-5deg b=37deg+-5deg
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
----------
aa=5.6+-0.03mm
----------
a=(50deg)
----------
aa=5.6+-0.03mm
----------
a=(50deg)
0000001401
(1)Pointer
(2)Injection timing aligning mark
(3)Fly weight
(4)The actual shape and direction may be different from this illustration.
Operation sequence
1. Turn the prestroke actuator OFF.
2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position.
3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching.
4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark.
5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------
----------
----------
----------
0000001701
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001801
C:Shim
----------
----------
----------
----------
0000001901
A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------
----------
----------
----------
0000002201 SPEED SENSOR
(A) Flyweight projection
(B) Pickup sensor
(c) Lock nut
Speed sensor installation
(1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L.
(This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1mm
----------
----------
L=0.8~1mm
----------
0000002301 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=375r/min Ra=8.3+-0.1mm
----------
----------
N1=375r/min Ra=8.3+-0.1mm
----------
0000002401 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1400r/min Ra=R1(14.8)mm
----------
----------
N1=1400r/min Ra=R1(14.8)mm
----------
0000002501 ACS
(A) Aneroid compensator
(B) Set screw
(C) Boost pressure inlet
(D) Rack positioning screw
(E): Aneroid compensator main body
(F) Boost compensator spring
(G): Aneroid compensator spring
(H): Adjusting notch
(I) Push rod
1. Instructions for adjusting the boost compensator with the aneroid compensator
(1)Select a pushrod to obtain L1 at full boost.
(2)Remove the aneroid compensator main body.
(3)Adjust the booster compensator stroke by turning the screw at (D.
(4)Adjust the beginning of boost compensator operation by turning the notch at (H).
(5)Install the aneroid compensator at full boost state.
(6)Turn (B)'s set screw so that the distance between the snapring and the body is L2.
(7)Screw in the aneroid compensator main body and adjust the point where it comes into play.
----------
L1=24+-0.5mm L2=1.5+-0.5mm
----------
----------
L1=24+-0.5mm L2=1.5+-0.5mm
----------
Timing setting ACS
(A) Set screw
(B) Push rod 1
(C) Push rod 2
(D) Cover
1. Aneroid compensator unit adjustment
(1)Select the push rod 2 to obtain L2.
(2)Screw in (A) to obtain L1.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
(3)As there is hysterisis, measure when the absolute pressure drops.
(4)Hysterisis must not exceed rack position = h1.
----------
N1=1400r/min L1=1.5+-0.5mm L2=24+-0.5mm h1=0.15mm
----------
Ra=R1(14.8)mm Rb=R1-0.5mm Pa=79.4+-2.7kPa(596+-20mmHg) Pb=58.7+-0.7kPa(440+-5mmHg) Q1=115.4+-1cm3/1000st Q2=(106.7)+-1.6cm3/1000st
----------
N1=1400r/min L1=1.5+-0.5mm L2=24+-0.5mm h1=0.15mm
----------
Ra=R1(14.8)mm Rb=R1-0.5mm Pa=79.4+-2.7kPa(596+-20mmHg) Pb=58.7+-0.7kPa(440+-5mmHg) Q1=115.4+-1cm3/1000st Q2=(106.7)+-1.6cm3/1000st
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Nissan-Diesel
Nissan-Diesel
Nissan-Diesel
Nissan-Diesel
107692-0040
INJECTION-PUMP ASSEMBLY